Case Study 1: Bakery

Background

This medium sized bakery produces premium quality flour based confectionery, cakes and steamed puddings using traditional Irish recipes.

Problem

The lean start initiative focused on the turnaround issues associated with the ‘post bake’ process.

Goal

To improve production flow, targeting trolleys, the de-thinning process, a FIFO system from cooling and to improve the efficiency of the pack-out process. The initiative set a target for a 20% productivity improvement in this process.

Results

Productivity improved by 87% measured on the average output per hour
Production hours reduced to a single shift
Annual labour cost saving of € 38,900 pa

Case Study 2: Fresh Salad Sector

Background

The company produces a wide range of pre-packed salads, soups and sandwich fillers.

Problem

The lean start initiative focused on reducing labour costs in the salad sector of the business.

Goal

To reduce the overall direct labour costs by 5 %.

Results

A Lean culture was embedded throughout all the preparation and packing process areas. An overall reduction of 12 % in direct labour was achieved Lean tools used were:

• Value stream mapping
• Theory of constraints
• Balancing throughput with demand
• Resource planning

Case Study 3: Handmade Chocolates

Background

This speciality chocolate maker produces handmade gourmet chocolates.

Problem

The lean start initiative focused on the production department, looking to Identify where waste was occurring.

Goal

To reduce labour costs, reduce waste and be able to quantify waste and to plan for seasonal fluxes

Results

Simple check sheets and visual management aids such as photos of the waste after each shift were found to be highly effective. A Lean culture was embedded throughout the company. Labour costs have been reduced by € 500k. Waste has been reduced by 10% and hidden waste has been identified. By planning for seasonal peak and troughs the stockholding has been reduced by 18% all the preparation and packing process areas.